Battery powered subsea pumping system

ABSTRACT

A battery powered pumping skid system comprises a frame, comprising a battery compartment and an equipment compartment; a battery disposed within the battery compartment; a motor operatively connected to the battery and disposed within the equipment compartment; a pump operatively connected to the motor and disposed within the equipment compartment; and a motor controller operatively connected to the battery and the motor and disposed within the equipment compartment. Optionally, one or more floatation compartments with one or more floats may be provided. Powered operation may be provided to a subsea device by deploying the battery powered pumping skid system subsea, either on an as needed or longer term basis, maneuvering the battery powered pumping skid system close to a subsea device, and, once in place, using the battery powered pumping skid system to perform one or more predetermined functions with respect to the subsea device, such as supplying a fluid from the pump to the subsea device using electrical power from the battery.

RELATION TO OTHER APPLICATIONS

This application claims priority through U.S. Provisional Application61/933,094 filed Jan. 29, 2014 and U.S. Provisional Application62/012,030 filed Jun. 13, 2014.

BACKGROUND

Some subsea devices can require power, potentially large amounts ofpower, to effect certain functionality. By way of example and notlimitation, blowout preventers (BOPS) currently have large accumulatorbottles on them that store hydraulic fluid under high pressures. Thisaccumulated power is used in the event of an emergency blowout or lossof control of the well to close the BOP rams. When closed, the BOP ramsare capable of shearing a drill pipe in the well bore and containing thewell bore pressures. The BOP accumulator systems have a number ofnegative implications, e.g. they take up a lot of space on the BOPstack; they weigh a lot; and they have reduced efficiency as water depthincreases.

Accordingly, skid supplied power may be used but skid architecturetypically uses power from a remotely operated vehicle (ROV) or anumbilical to accomplish tasks like these. Normal skid architecture knownin the industry uses power from the ROV or an umbilical to provide thepower required to drive a motor/pump in a subsea environment. However anROV may not be able to supply enough power to close the BOP rams withinthe specified time outlined by API 53. No current ROV-based BOP skid inthe industry can meet the requirements set by API 53.

FIGURES

Various figures are included herein which illustrate aspects ofembodiments of the disclosed inventions.

FIG. 1 is a block diagram of an exemplary system;

FIG. 2 is a top view schematic diagram of an exemplary skid;

FIG. 3 is a view in partial perspective of an exemplary battery;

FIG. 4 is a block diagram of an exemplary battery module;

FIG. 5 is a view in partial perspective of an exemplary pump and motor;

FIG. 6 is a side view in partial perspective of a further exemplaryskid; and

FIG. 7 is a block view in partial perspective of an exemplary skiddeployment.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

The various powered pumping skid systems disclosed herein contain one ormore batteries, electric motors, motor controllers and/or variablefrequency drives, electrical contacts, and pumps. In combination, theseelements may be configured to be capable of pumping seawater or otherfluid media at power rates from around zero to over 500 horsepower. Thedisclosed systems will typically be capable of pumping over 100 GPM at5,000 PSI for two minutes before requiring recharge, but the actual flowrate will be controllable by varying the motor speed, if required. Runtime may be longer than two minutes when running at less than fullpressure or full speed.

A block diagram of battery powered subsea pumping skid 1 (FIG. 2) or 2(FIG. 6) is shown in FIG. 1 where the disclosed battery powered subseapumping skids (1 (FIG. 2), 2 (FIG. 6)) use batteries to provide theamounts of power required to drive a motor/pump in a subsea environment.Using battery powered subsea pumping skid 1 or 2, amounts of powerrequired for certain subsea functionality may be supplied in a shortperiod of time that could not otherwise be supplied by a work classremotely operated vehicle (ROV) such as ROV 300 (FIG. 7).

Referring now to FIGS. 1 and 2, in an embodiment battery powered pumpingskid 1 comprises frame 10; equipment compartments 102, 105, 109; one ormore battery modules 40 disposed within battery compartments 104, 106;motor 20 operatively connected to one or more battery modules 40 anddisposed within one or more of equipment compartments 102, 105, 109, andmore preferably within equipment compartment 105; pump 30 operativelyconnected to motor 20 and disposed within one or more of equipmentcompartments 102, 105, 109; motor controller 22 operatively connected toone or more battery modules 40 and to motor 20, where motor controller22 is disposed within one or more of equipment compartments 102, 105,109. In some embodiments, battery powered pumping skid skid 1 furthercomprises one or more floatation compartments 101, 103, 107, 108 and oneor more floats 50 disposed within at least one of floatationcompartments 101, 103, 107, 108.

In embodiments, battery powered pumping skid 1 may weigh approximately3,500 pounds (lbs) in air, be neutrally buoyant in seawater, and/or bearound 9 feet by 5 feet by 20 inches in dimension.

Typically, frame 10 is configured to be neutrally buoyant in seawaterand made with extruded aluminum. Frame 10 may be configured to bemountable to a work class ROV, e.g. ROV 300 (FIG. 7), or a work classROV cage and may further be configured to be affixed to a subsea pieceof equipment such as a tree, a manifold, a blowout preventer (BOP)stack, or the like, or a combination thereof. In certain embodiments,frame 10 may be configured to allow battery powered pumping skid 1 to bedisposed on or proximate sea floor 350 (FIG. 7).

Frame 10 typically comprises one or more battery compartments, e.g. 104and 106, and is typically substantially rectangular, although it neednot be so shaped, although. substantially rectangular shape is typicallydesired if battery powered pumping skid skid 1 is to be attached orotherwise mounted to an ROV.

In embodiments, frame 10 comprises a plurality of floatationcompartments 101, 103, 107, 108 and float 50 comprises a correspondingplurality of floats 50, each float 50 of the plurality of floats 50disposed within a corresponding one of plurality of floatationcompartments 101, 103, 107, 108. If present, one or more floatationcompartments 50 are typically disposed at predetermined portions offrame 50 which, in a preferred embodiment, comprises each of the fourcorners of frame 50. Other locations are also possible, by way ofillustration and not limitation including top, bottom, and/or at thesides of frame 50.

Motor 20 may comprise an oil-filled, pressure compensated motor 20, suchas one comprising a 16 pole permanent magnet 3 phase AC motor capable of400 shaft horsepower at 1,200 RPM. Motor 20 may also comprise a variablefrequency drive 24.

Motor controller 22 may comprise a pressure tolerant, oil filledcontroller capable of driving the 400 HP motor from a DC source of435-630 Volts.

One or more equipment compartments, e.g. 102, 105, 109, may be presentand variously configured. In an embodiment, motor compartment 105 isdisposed substantially within a middle interior portion of frame 10,such as by having motor 20 disposed within motor compartment 105; pumpcompartment 109 is disposed proximate a middle exterior section of frame10, with pump 30 disposed within pump compartment 109; and controllercompartment 102 is disposed proximate a middle exterior section of frame10 opposite pump compartment 109, where motor controller 22 is disposedwithin controller compartment 102. However, as the need arises, any ofthese (motor 20, motor controller 22, pump 30) may be disposed at leastpartially within a single equipment compartment or span severalequipment compartments, e.g. 102, 105, 109.

One or more battery modules 40 may be disposed within one or morebattery compartments. In typical embodiments, first battery compartment104 and second battery compartment 106 are present, each disposedtowards an outer perimeter of frame 10 proximate a middle section offrame 10, but disposed opposite each other. In such embodiments, firstbattery module 40 a is typically disposed within first batterycompartment 104 and second battery module 40 b disposed within secondbattery compartment 106.

Referring additionally to FIGS. 3 and 4, one or more battery modules 40may comprise pressure tolerant battery 42 (FIG. 3) which may be apressure tolerant lithium polymer battery 42 (FIG. 3). Each batterymodule 40 may comprise a number of separate battery modules 40, e.g. sixseparate modules 4, where each battery module 40 contains apredetermined number of batteries 42.

In embodiments, battery 42 may comprise battery housing 41, one or morepressure tolerant battery cells 42 disposed within battery housing 41,and one or more contacts 44 configured to prevent live pins, i.e. pinsthat are conducting electricity, until everything is plugged in and asignal is received to become conductive.

In embodiments, battery housing 41 may comprise an oil-filled, pressurecompensated housing 41. In a further embodiment, battery housing 41 maycomprise a pressurized housing, by way of illustration and notlimitation including a one atmosphere subsea canister which may thencontain one or more batteries 42 adapted for use in such a canister. Ina further embodiment, battery housing 41 may comprise a potted unitwhich contains no oil inside and in which an epoxy fills all voids inbetween cells and the like.

Each pressure tolerant battery cell 42 may further comprise a lithiumpolymer pressure tolerant battery cell which may be configured toprovide around 500 VDC at up to 900 amperes. In other configurations,pressure tolerant cells 42 may be configured to allow one or morebattery modules 40 to provide a predetermined voltage, e.g. 555 Volts DCnominal, having a predetermined discharge capacity, e.g. 5 Ampere hours,and be configured to discharge continuously at a predetermined rate,e.g. 30C 150 Amps and 50C peak 250 Amps.

In typical embodiments, battery modules comprise a 150 slp configurationof lithium polymer pressure tolerant cells 42, although, as will befamiliar to those of ordinary skill in the battery arts, other batterytypes may be used, by way of illustration and not limitation includinglithium iron phosphate, nickel metal hydrate, or the like, or acombination thereof. Alternatively, other battery modules may be used,by way of illustration and not limitation including 10 s2p modules andthe like.

In an alternative embodiment, to allow for long term standalone subseadeployment without the need for recharging, one or more thermalbatteries 43 may be used. These may be configured to supply sufficientamounts of power for functions such as blowout preventer (BOP)intervention work and the like and may include long shelf life.

In embodiments, batteries 42 will be rechargeable subsea such as via anROV umbilical or other power source or at a different location such astopside.

Typically, battery powered subsea pumping skid 1 will be able to operateat full pressure on less than all of battery modules 40 being availablewithout damage to batteries 42. This allows battery powered subseapumping skid 1 to continue to perform in the event of an emergency orwhere one or more of battery modules 40 is down or otherwiseunavailable.

Referring back to FIG. 1 and to FIG. 5, pump 30 is operatively connectedto motor 20 and typically comprises a high flow, high volume pump. Pump30 is further typically configured to be capable of pumping seawater orother fluid media at power rates from around zero to over 500 horsepowerwith a flow rate of around 110 GPM at 1,200 RPM, at up to around 5,000PSI. Pump 30 may comprise an axial piston pump. Pump may further containno oil for lubrication.

Battery recharge port 11 may be present and operatively connected to oneor more battery modules 40, especially where battery module 40 comprisesa rechargeable battery 42. Typically, battery recharge port 11 comprisesa remotely operated vehicle (ROV) umbilical compatible battery rechargeport.

In a further embodiment, referring now to FIG. 6, battery poweredpumping skid system 2 comprises substantially rectangular frame 210configured to be neutrally buoyant in seawater, frame 210 comprisingfirst row 211, third row 213 disposed opposite first row 211 withinframe 210, and second row 212 disposed intermediate first row 211 andthird row 213. Each row 211, 212, 213 comprises three columns: 214, 215,216. The three rows 211, 212, 213 and three columns 214, 215, 216 definenine separate compartments. Battery powered pumping skid system 2further comprises one or more floats 250 disposed in outer compartmentsfirst row 112 and/or third row 114. Various covers, e.g. 217 and 221,may cover one or more individual compartments or portions thereof.

One or more first battery modules 240 (shown in FIG. 6 but obscured bycover 217) may be disposed within middle compartments first row 211 andthird row 213.

Motor 220 (shown in FIG. 6 but obscured by cover 221) is operativelyconnected to at least one of the first battery modules 240 and typicallydisposed within an interior compartment of second row 212. Motorcontroller 222 (shown in FIG. 6 but obscured by cover 223) is typicallyoperatively connected to at least one of the first battery modules 240and motor 220, and is typically disposed in a middle compartment ofouter column 216.

Pump 230 is operatively connected to motor 220 and is typically disposedwithin an outer compartment of column 214.

One or more umbilical interfaces 218 may be present and adapted toprovide an interface between an umbilical such as an ROV umbilical andone or more components in battery powered pumping skid system 2 such asmotor 220, motor controller 222, pump 230, and/or battery modules 240.In certain embodiments, one or more battery modules 240 may comprise oneor more rechargeable batteries 42 and umbilical interface 218 mayfurther comprise a battery recharge interface operatively connected torechargeable battery 42.

Additionally, one or more instruments 219 may be disposed on, within, orproximate frame 210 and be operatively in communication with umbilicalinterface 218, such as, by way of example and not limitation, a pressuretransducer, a flow meter, a temperature sensor, and the like, or acombination thereof, where instruments 219 may be configured to relayperformance information in real time using umbilical 303 (FIG. 7)operatively connected to umbilical interface 218 to another instrumentdevice such as a processor on a remotely operated vehicle, e.g. vessel320 (FIG. 7).

In the operation of exemplary embodiments, referring additionally toFIG. 7, a battery powered subsea pumping skid such as battery poweredsubsea pumping skid 1 (FIG. 2) or battery powered subsea pumping skid 2(FIG. 6 and FIG. 7) is maneuvered close to a subsea device such as BOP310. Battery powered subsea pumping skid 2 may have a full set ofcharged batteries 42 (FIG. 2) and/or may have its battery modules 40(FIG. 2) charged once disposed subsea, such as via battery recharge port11 operatively connected to ROV umbilical compatible battery rechargeport 302.

Once in place, skid 1 (FIG. 2) (or skid 2 (FIG. 6)) is used to performone or more functions with respect to the subsea device, by way ofexample and not limitation including closing BOP rams by using pump 30driven by motor 20 to deliver pressure and flow to the BOP rams.

When deployed, one or more instruments 219 (FIG. 6) may be placed intocommunication with a monitoring system such as ROV 300 or topside vessel320, such as via umbilical 303 operatively connected to umbilicalinterface 218. Instruments 219 can then be used to monitor one or moredesired environmental characteristics such as pressure, flow,temperature, and the like, or a combination thereof, and relay theinformation in real time via back to the monitoring system.

In certain embodiments, a battery powered subsea pumping skid (1 (FIG.2) or 2 (FIG. 7)) are deployed on as-needed basis. In other embodiments,the battery powered subsea pumping skid may be deployed long term subseawithout the need for continuous maintenance and charging of the powersupply. This enables a standalone solution, e.g. a BOP interventionsolution, to be deployed substantially continuously for a length oftime, e.g. 2 months or less, for standalone or ROV controlled operation.

The foregoing disclosure and description of the inventions areillustrative and explanatory. Various changes in the size, shape, andmaterials, as well as in the details of the illustrative constructionand/or an illustrative method may be made without departing from thespirit of the invention.

We claim:
 1. A battery powered pumping skid system, comprising: a. aframe, comprising: i. a battery compartment; and ii. an equipmentcompartment; b. a battery disposed within the battery compartment; c. amotor operatively connected to the battery and disposed within theequipment compartment; d. a pump operatively connected to the motor anddisposed within the equipment compartment; and e. a motor controlleroperatively connected to the battery and the motor and disposed withinthe equipment compartment.
 2. The battery powered pumping skid system ofclaim 1, further comprising: a. a floatation compartment; and b. a floatdisposed within the floatation compartment
 3. The battery poweredpumping skid system of claim 2, wherein: a. the floatation compartmentcomprises a plurality of floatation compartments; and b. the floatcomprises a corresponding plurality of floats, each float of theplurality of floats disposed within a corresponding one of plurality offloatation compartments.
 4. The battery powered pumping skid system ofclaim 1, wherein the frame is configured to be neutrally buoyant inseawater.
 5. The battery powered pumping skid system of claim 1,wherein: a. the frame is substantially rectangular; b. the batterycompartment comprises a first battery compartment and a second batterycompartment, each disposed towards an outer perimeter of the frameproximate a middle section of the frame; and c. the battery comprises afirst battery disposed within the first battery compartment and a secondbattery disposed within the second batter compartment.
 6. The batterypowered pumping skid system of claim 1, wherein: a. the frame issubstantially rectangular; b. the equipment compartment comprises: i. amotor compartment disposed substantially within a middle interiorportion of the frame; ii. a pump compartment disposed proximate a middleexterior section of the frame; and iii. a controller compartmentdisposed proximate a middle exterior section of the frame opposite thepump compartment; c. the motor is disposed within the motor compartment;d. the pump is disposed within the pump compartment; and e. the motorcontroller is disposed within the controller compartment.
 7. The batterypowered pumping skid system of claim 1, further comprising a batteryrecharge port operatively connected to the battery, the batterycomprising a rechargeable battery.
 8. The battery powered pumping skidsystem of claim 7, wherein the battery recharge port comprises aremotely operated vehicle umbilical compatible battery recharge port. 9.The battery powered pumping skid system of claim 1, wherein the batterycomprises a pressure tolerant battery.
 10. The battery powered pumpingskid system of claim 1, wherein the battery comprises a pressuretolerant lithium polymer battery.
 11. The battery powered pumping skidsystem of claim 1, wherein the battery compartment comprises a oneatmosphere subsea battery housing.
 12. The battery powered pumping skidsystem of claim 1, wherein the battery comprises a battery modulecomprising: a. a battery housing; b. a pressure tolerant battery celldisposed within the battery housing; and c. a contact configured toprevent live pins until everything is plugged in and a signal isreceived.
 13. A method of providing power to a subsea device,comprising: a. deploying a battery powered pumping skid system subsea,the battery powered pumping skid system comprising: i. a frame,comprising:
 1. a battery compartment; and
 2. an equipment compartment;ii. a battery disposed within the battery compartment; iii. a motoroperatively connected to the battery and disposed within the equipmentcompartment; iv. a pump operatively connected to the motor and disposedwithin the equipment compartment; and v. a motor controller operativelyconnected to the battery and the motor and disposed within the equipmentcompartment; b. maneuvering the battery powered pumping skid systemclose to a subsea device; and c. once in place, using the batterypowered pumping skid system to perform a predetermined function withrespect to the subsea device, the predetermined function comprisingsupplying a fluid from the pump to the subsea device using electricalpower from the battery.
 14. The method of providing power to a subseadevice of claim 13, wherein the predetermined function comprises closinga blowout preventer (BOP) ram by using the pump driven by the motor todeliver fluid pressure and flow to the BOP ram.
 15. The method ofproviding power to a subsea device of claim 13, further comprising: a.providing an instrument; and b. placing the instrument intocommunication a monitoring system.
 16. The method of providing power toa subsea device of claim 15, further comprising placing the instrumentinto communication a monitoring system via an umbilical interface. 17.The method of providing power to a subsea device of claim 15, furthercomprising: a. using the instrument to monitor a predetermined sensedcharacteristic; and b. relaying the sensed characteristic in real timevia back to the monitoring system.
 18. The method of providing power toa subsea device of claim 17, wherein the sensed characteristic comprisespressure, flow, and/or temperature.
 19. The method of providing power toa subsea device of claim 13, further comprising deploying the batterypowered pumping skid system on as-needed basis.
 20. The method ofproviding power to a subsea device of claim 13, further comprisingdeploying the battery powered pumping skid system on a long term basissubsea without a need for continuous maintenance and charging of thebattery.